Description:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
The Patents Rules, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

A DOOR ASSEMBLY, A HINGE ASSEMBLY AND A METHOD THEREOF FOR A VEHICLE

APPLICANT:

TVS MOTOR COMPANY LIMITED, an Indian Company at: “Chaitanya”, No.12 Khader Nawaz Khan Road, Nungambakkam, Chennai 600 006.

The following specification particularly describes the invention and the manner in which it is to be performed.

TECHNICAL FIELD
[0001] The present subject matter relates generally to a door assembly of a vehicle. More particularly but not exclusively, the present subject matter relates to a hinge assembly for the door assembly of the vehicle for adjustment of the door assembly across multiple directions while ensuring precise alignment, manufacturing and assembling of the door assembly.

BACKGROUND
[0002] Vehicles in general have a door assembly that comprises externally mounted hinge assemblies. The external mounted hinge assembly is often visible from the outside of the vehicle when the door assemblies are closed. This externally mounted hinge assembly disrupts the smooth airflow over the vehicle, leading to increased drag and reduced fuel efficiency. Since the smooth contoured profile of a vehicle is crucial for not only for aerodynamics but also important for the consumer perception due to aesthetics, the external hinge assembly is not desirable as it often disrupts the smooth lines and symmetry of the vehicle's body. This is due to the created visible gaps and protrusions that can be visually distracting and may interrupt the vehicle's overall design flow. Further, the external hinge assemblies are more exposed to environmental elements and potential damage, such as rust, dirt, or accidental impacts. Furthermore, the hinge assembly plays a crucial role in enabling the smooth opening and closing of door panels. Earlier, the hinge assembly were often manufactured using casting methods where molten metal is poured into moulds to create the shape of the hinge assembly. However, this casting process could lead to complications in achieving the required geometry for hinge assembly, especially when dealing with intricate shapes and designs.
[0003] Also, in the majority of vehicles, the door panels are assembled in the middle or rear portion often known as cabin assembly. The cabin assembly is often the enclosed compartment of the vehicle where the passengers sit. The vehicle also consists of both the B-pillars and C-pillars that form the structural components of the vehicle's body. The B-pillar is the vertical support pillar which is conventionally in the center or towards the rear region along the vehicle's side. This means that in case typically the B-pillar separates the portions accommodating the front occupants and the rear occupants. On the other hand, the C-pillar is the pillar at the back of the rear door panel. These pillars play a crucial role in providing structural integrity to the vehicle's body and ensuring the safety of passengers in the event of a collision. Further, the inclusion of B-pillar and C-pillar in the middle and/or rear portion of the vehicle is done to control variations during the assembling of the door panels. The B-pillar and the C-pillar are crucial for proper alignment of the door panels, structural integrity and overall safety of the vehicle. This is also required for the proper functioning of door locking mechanisms. The assembling of the door panels involves the process of putting together the various components of the door assembly in such a way so as to ensure correct fitting and smooth operation. However, assembling the B-pillar and C-pillar comes with its own disadvantages as it affects the overall weight and cost of the vehicle because of the materials used in these structural pillars. The assembling process also becomes costly due to the complexity of joining these pillars with the other components of the middle and/or rear portion of the vehicle. Additionally, during the manufacturing process, there can be minor variations or deviations in the placement of the B-pillars and the C-pillars due to factors like thermal expansion, material tolerances, welding or/and dimensional inaccuracies.
[0004] Various efforts have been undertaken to address this issue. One such solution being shifting the B-pillar from the rear portion and placing it directly on the front portion often known as the chassis assembly. The front portion being part of the frame assembly is the main framework of the vehicle, thereby providing a foundation for all other components to be attached. This relocation often makes the design more weight-effective and cost-effective. However, this solution presents some challenges, such as placing the B-pillar directly on the front portion could result in variations in the B-pillar and the rear portion which could further lead to door locking issues. The B-pillar needs to be precisely aligned and securely connected to the rear portion to ensure smooth operation of the door locking mechanism. Further, moving the B-pillar to the front portion may cause problems with gaps and flushness between the door assembly and the body of the vehicle. Gaps are spaces between the door assembly and surrounding body panels, while flushness refers to the alignment of the surface of the door assembly with the adjacent body panels of the vehicle. This may adversely impact the aerodynamics of the vehicle and could also compromise the vehicle’s aesthetics.
[0005] Controlling door assembly mounting variation is a critical aspect in the vehicle manufacturing. The proper door assembly mounting ensures consistent quality and proper operation of the door panels. The door assembly mounting variation refers to differences or deviations in how the door panels are attached and aligned to the vehicle’s body during assembling. Uncontrolled variations can result in several issues such as improper fit and finish, functionality problem, noise and vibration, water and dirt entry, or the like.
[0006] The mounting, assembling and manufacturing of the door assembly involves the process of attaching, making and fabricating the door panels securely to the vehicle's body so that they can open and close smoothly without any obstruction. If the door assembly is not mounted precisely, it might not align correctly with the receptors, leading to problems with the locking mechanism. Further, if there is a deviation during mounting, the door panels might not move freely, causing them to get stuck or jammed. This could lead to the problem of inconvenience faced by the passengers and can even pose a safety hazard to the passengers, especially in emergency situations where quick exit from the vehicle might be necessary. Thickness of the door panel of existing vehicles is excessive. This not only makes the opening and closing of the door panel cumbersome but also creates hinderance during ingress and egress. Further, door panels with higher thickness result in addition of unnecessary weight to the vehicle. Furthermore, the poorly mounted door assembly can create rattling noises or excessive vibrations while driving. These vibrations can propagate through the vehicle and negatively impact the driving experience, comfort, and overall quality of the vehicle.
[0007] Therefore, there is a need to address the above-mentioned problems in order to provide proper and effective placement of the door assembly and the structural pillars in the vehicle while ensuring interoperability of the hinge assembly across various vehicular components and designs; effective weight optimization and ease of manufacturing and assembly.

BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The details are described with reference to an embodiment of a door assembly along with the accompanying figures. The same numbers are used throughout the drawings to reference similar features and components.
[0009] Figure 1 illustrates a perspective view of portion of a vehicle having door assemblies and a rear portion in one embodiment of the invention.
[00010] Figure 2 illustrates a side view of the vehicle having the door assembly and the rear portion in one embodiment of the invention.
[00011] Figure 3 illustrates a side perspective view of the vehicle having two door assemblies and the expanded view of the hinge assembly of the door assembly in closed condition along with the lateral axis L-L’ and longitudinal axis D-D’ of the vehicle in one embodiment of the invention.
[00012] Figure 4 illustrates a side perspective view of the door assembly from an interior of the vehicle in one embodiment of the invention.
[00013] Figure 5 illustrates a side perspective view of the door assembly from an exterior of the vehicle in one embodiment of the invention.
[00014] Figure 6 illustrates a perspective view of a hinge assembly having a first member being attached to a B-pillar in one embodiment of the invention.
[00015] Figure 7 illustrates another perspective view of the hinge assembly showing axis P-P’ in one embodiment of the invention.
[00016] Figure 8 illustrates an exploded view of the hinge assembly in one embodiment of the invention.
[00017] Figure 9 illustrates another exploded view of the hinge assembly with the first member and second member along with a plurality of fasteners in one embodiment of the invention.
[00018] Figure 10 illustrates a side view of the vehicle having the door assembly in closed condition in one embodiment of the invention.
[00019] Figure 11 illustrates the top view of the vehicle having the door assembly in closed condition (detail B) and opened condition (detail A) in one embodiment of the invention.
[00020] Figure 12 illustrates an expanded view of the door assembly in opened condition (detail A) in one embodiment of the invention.
[00021] Figure 13 illustrates an expanded view of the door assembly in closed condition (detail B) one embodiment of the invention.
[00022] Figure 14 illustrates a flow chart depicting a method for an adjustment of a door panel of a door assembly in a plurality of directions during assembly of a vehicle.

SUMMARY OF THE INEVENTION
[00023] The present invention relates to a door assembly of a vehicle. The door assembly comprises a door panel which is hingably mounted on the vehicle, a hinge assembly that is configured to hingably mount the door panel on the vehicle. The hinge assembly comprises a first member being attached to a predefined portion of the vehicle, a second member being attached to the door panel, a pivot member being configured to pivotably connect the first member and the second member. The hinge assembly also comprises a plurality of holes which are provided on the first member and the second member. The plurality of holes has an oblongated profile to enable an adjustment of the door panel in a plurality of directions.
[00024] The present invention relates to a hinge assembly which is configured to hingably mount one or more door panels on a vehicle. The hinge assembly comprising a first member being attached to a predefined portion of a frame assembly of the vehicle, a second member being attached to the door panel, a pivot member being configured to pivotably connect the first member and the second member, and a plurality of holes being provided on the first member and the second member. The plurality of holes has an oblongated profile to enable an adjustment of the door panel in a plurality of directions.
[00025] The present invention relates to a vehicle. The vehicle comprises a front portion being configured to accommodate a driver seat, a rear portion being configured to accommodate a passenger seat and a frame assembly being configured to provide a skeletal support to the vehicle. The frame assembly comprises at least two B-pillars being disposed between the front portion and the rear portion, at least two C-pillars being disposed in the rear portion of the vehicle. The vehicle also comprises a door assembly being hingably attached to the vehicle. The door assembly comprises one or more door panels being hingably mounted on the vehicle, and a hinge assembly being configured to hingably mount the door panel on the vehicle. The hinge assembly comprises a first member being attached to a predefined portion of the frame assembly of the vehicle, a second member being attached to the door panel, a pivot member being configured to pivotably connect the first member and the second member, and a plurality of holes being provided on the first member and the second member. The plurality of holes has an oblongated profile to enable an adjustment of the door panel in a plurality of directions.
[00026] The present invention relates to a method for an adjustment of one or more door panels of a door assembly in a plurality of directions during assembly of a vehicle. The method comprises the steps of a first step that includes loosening a plurality of fasteners, the plurality of fasteners being fastened through a plurality of holes, the plurality of holes have an oblongated profile and the plurality of holes being provided on a first member and a second member of a hinge assembly of a door assembly, thereby loosening an attachment of the door panel from the first member of the hinge assembly, wherein the second member being connected to a frame assembly of the vehicle. The method comprises a second step of selecting one direction from a plurality of directions, the plurality of directions comprising a direction along a longitudinal axis of the vehicle, a direction along a lateral axis of the vehicle, and a direction perpendicular to the lateral axis of the vehicle. The third step of the method includes moving the door panel along one or more of the plurality of directions along with the plurality of fasteners within the oblongated profile of the plurality of openings to enable an alignment of the door panel with a striker member of the door assembly, the striker member being configured to receive at least one predefined portion of the door panel at a closed condition of the door panel. Finally, the method comprises a fourth step of tightening the plurality of fasteners on the first member and the second member thereby fixing a position of the door panel on the vehicle.

DETAILED DESCRIPTION
[00027] The present invention therefore discloses a door assembly with a hinge assembly. The hinge assembly is designed to fit on different parts of the vehicle. A first portion is attached on a predefined portion of the vehicle while a second portion is attached on a door panel of the door assembly. A pivot member securely fastens the first member and the second member by pivotably connecting the first member and the second member while also providing a bearing surface for the rotation of the hinge assembly.
[00028] As per one embodiment of the invention, a door assembly for a vehicle having a frame assembly is disclosed. The door assembly comprises one or more door panels being hingably mounted on the vehicle, a hinge assembly being configured to hingably mount the door panel on the vehicle. The hinge assembly comprises a first member being attached to a predefined portion of the vehicle and a second member being attached to the door panel. The hinge assembly also comprises a pivot member being configured to pivotably connect the first member and the second member, and a plurality of holes that are provided on the first member and the second member. The plurality of holes has an oblongated profile to enable an adjustment of the door panel in a plurality of directions.
[00029] As per one embodiment of the invention, in the door assembly, the first member and the second member are plate members. The plate members are configured to enable the adjustment of the door panel in the plurality of directions. The plurality of directions comprises a direction along a lateral axis of the vehicle, a direction along a longitudinal axis of the vehicle and a direction perpendicular to the lateral axis of the vehicle.
[00030] As per one embodiment of the invention, in the door assembly, the first member of the hinge assembly is disposed on an internal surface of the predefined portion of the vehicle, and the second member is attached on an internal surface of the door panel. The door panel are configured to swingably move between a closed and an opened condition to facilitate an entry and an exit of a user of the vehicle.
[00031] As per one embodiment of the invention, the door assembly comprises a striker member. The striker member is attached to a predefined portion of the vehicle. The striker member is configured to receive at least one predefined portion of the door panel at the closed condition of the door panel. The adjustment of the door panel is configured to achieve an appropriate alignment of the door panel with the striker member.
[00032] As per one embodiment of the invention, in the door assembly, a plurality of fasteners is configured to mount the first member to the predefined portion of the vehicle, and the plurality of fasteners are being configured to attach the second member on the door panel of the vehicle. The plurality of fasteners is configured to be received in the plurality of holes such that the door panel is configured to be adjusted in the plurality of directions while the plurality of fasteners being partially fastened into the plurality of holes.
[00033] As per one embodiment of the invention, in the door assembly, the hinge assembly comprises at least two first members and at least two second members and the predefined portion of the vehicle being a B-pillar of frame assembly of the vehicle.
[00034] As per one embodiment of the invention, in the door assembly, the door panel is a half door panel, the half door panel is configured to shut a bottom half of a doorway.
[00035] As per one embodiment of the invention, in the door assembly, the internal surface of the door panel is provided with a niche. The niche is configured to receive and store a plurality of articles.
[00036] As per one embodiment of the invention, in the door assembly, a lock is provided. The lock is configured to secure the door assembly in the closed condition.
[00037] As per one embodiment of the invention, a hinge assembly is disclosed. The hinge assembly is configured to hingably mount one or more door panels on a vehicle. The hinge assembly comprises a first member which is attached to a predefined portion of a frame assembly of the vehicle and a second member which is attached to the door panel. The hinge assembly also comprises a pivot member which is being configured to pivotably connect the first member and the second member, and a plurality of holes being provided on the first member and the second member. The plurality of holes has an oblongated profile to enable an adjustment of the door panel in a plurality of directions.
[00038] As per one embodiment of the invention, in the hinge assembly, the pivot member being a shaft.
[00039] As per one embodiment of the invention, the shaft is made of a material having a low friction on a peripheral surface of the shaft. The shaft belongs to a group comprising pins, rivets and bolts.
[00040] As per one embodiment of the invention, in the hinge assembly, the first member and the second member comprise a plurality of pivot openings. The plurality of pivot openings are configured to receive the pivot member in a hollow cavity which is formed upon an alignment of the plurality of pivot openings along a pivot axis to enable a pivotable connection between the first member and the second member.
[00041] As per one embodiment of the invention, in the hinge assembly, a plurality of spacer members is being configured to affix the pivot member into the hollow cavity upon the alignment of the first member and the second member along the pivot axis. The plurality of spacer members comprises a top bush, a bottom bush and a pair of middle bushes.
[00042] As per one embodiment of the invention, the plurality of spacer members is made up of the material having low friction.
[00043] In yet another embodiment of the invention, a vehicle is disclosed. The vehicle comprises a front portion being configured to accommodate a driver seat, a rear portion being configured to accommodate a passenger seat and a frame assembly being configured to provide a skeletal support to the vehicle. The frame assembly comprises at least two B-pillars being disposed between the front portion and the rear portion; and at least two C-pillars being disposed in the rear portion of the vehicle. The vehicle also comprises a door assembly, being hingably attached to the vehicle. The door assembly comprises one or more door panels being hingably mounted on the vehicle. The door assembly also comprises a hinge assembly being configured to hingably mount the door panel on the vehicle. The hinge assembly comprises a first member being attached to a predefined portion of the frame assembly of the vehicle and a second member being attached to the door panel. The hinge assembly also comprises a pivot member being configured to pivotably connect the first member and the second member, and a plurality of holes. The plurality of holes is provided on the first member and the second member. The plurality of holes has an oblongated profile to enable an adjustment of the door panel in a plurality of directions.
[00044] As per one embodiment of the invention, in the vehicle, the rear portion being configured to have a recess. The recess is configured to accommodate a peripheral portion of the door panel in order to enable a flush closing of the door panel with a body of vehicle.
[00045] As per one embodiment of the invention, in the vehicle, the predefined portion of the vehicle for connecting the first member being an internal surface of one of the at least two B-pillars.
[00046] As per one embodiment of the invention, in the vehicle, a cushioning is provided on a surface of the peripheral portion of the door panel in contact with the recess in order to dampen a shock impulse. The shock impulse is caused by a movement of the door panel between a closed and an opened condition.
[00047] In yet another embodiment of the invention, a method for an adjustment of one or more door panels of a door assembly in a plurality of directions during assembly of a vehicle is disclosed. The method comprises the steps of a first step that includes loosening a plurality of fasteners that are fastened through a plurality of holes. The plurality of holes has an oblongated profile and the plurality of holes are provided on a first member and a second member of a hinge assembly of a door assembly thereby loosening an attachment of the door panel from the first member of the hinge assembly, wherein the second member is connected to a frame assembly of the vehicle. The method comprises a second step of selecting one direction from a plurality of directions, the plurality of directions comprising a direction along a longitudinal axis of the vehicle, a direction along a lateral axis of the vehicle, and a direction perpendicular to the lateral axis of the vehicle. The third step of the method includes moving the door panel along one or more of the plurality of directions along with the plurality of fasteners within the oblongated profile of the plurality of openings to enable an alignment of the door panel with a striker member of the door assembly, the striker member being configured to receive at least one predefined portion of the door panel at a closed condition of the door panel. Finally, the method comprises a fourth step of tightening the plurality of fasteners on the first member and the second member thereby fixing a position of the door panel on the vehicle.
[00048] The embodiments of the present invention will now be described in detail with reference to an embodiment in a seat assembly along with the accompanying drawings. However, the disclosed invention is not limited to the present embodiments.
[00049] Figure 1 illustrates a perspective view of a portion of a vehicle 100 having two door assemblies 200 and a rear portion 103 in one embodiment of the invention. Figure 2 illustrates a side view of the vehicle 100 having the door assembly 200 and the rear portion 103 with one of the at least two C-pillars 105 in one embodiment of the invention. Figure 3 illustrates a side perspective view of the vehicle 100 having two door assemblies 200 and the expanded view of the hinge assembly 300 of the door assembly 200 in closed condition along with the lateral axis L-L’ and longitudinal axis D-D’ of the vehicle 100 in one embodiment of the invention. Figure 1, Figure 2, and Figure 3 have been taken together for discussion. The vehicle 100 may be one or more of a two-wheeled vehicle, three wheeled vehicle or other multi wheeled vehicles. The vehicle 100 comprises a front portion 102, a rear portion 103, and a frame assembly 101. The front portion 102 accommodates a driver seat. The rear portion 103 accommodates a passenger seat. The frame assembly 101 provides a skeletal support to the vehicle 100 and mounts various critical components along the length of the vehicle 100. The front portion 102 is often a chassis assembly102 that acts as a foundation for placing the various components on the vehicle 100. The rear portion 103 is often a cabin assembly placed at the rear end of the vehicle 100. The longitudinal axis D-D’ and the lateral axis L-L’ are along the length and breadth respectively of the vehicle 100. The axis D-D’ is along the length of the vehicle 100 denoting front direction F and rear direction R of the vehicle 100 in one embodiment of the invention. The axis L-L’ is along the breadth of the vehicle 100 denoting left direction L and right direction R’ of the vehicle 100 in one embodiment of the invention. The frame assembly 101 comprises at least two B-pillars 104 and at least two C-pillars 105. One of the at least two B-pillars 104 and one of the at least two C-pillars 105 are provided on each of a right side of the vehicle 100. One of the at least two B-pillars 104 and one of the at least two C-pillars 105 are provided on each of a left side of the vehicle 100. The at least two B-pillars 104 are disposed between the front portion 102 and the rear portion 103. The at least two C-pillars 105 are disposed in the rear portion 103 of the vehicle 100. The vehicle 100 comprises a door assembly 200, being hingably attached to the vehicle 100. The door assembly 200 also comprises a hinge assembly 300 being configured to hingably mount the door panel 201 (as shown in Figure 6) on the vehicle 100. The arrangement of the at least two B-pillars 104 on the vehicle 100 departs from the conventional approach of integrating the at least two B-pillars 104 on the rear portion 103 of the vehicle 100. Here, the at least two B-pillars 104 are placed directly on the front portion 102 of the vehicle 100 that results in potential weight reduction and cost-effectiveness thereby eliminating the need for additional components on the rear portion 103 of the vehicle 100 which further indirectly addresses the issues associated with assembling door panels 201 and their locking.
[00050] The embodiments shown in Figure 4 and Figure 5 illustrate internal and external perspective views respectively of the door assembly 200 of the vehicle 100 (as shown in Fig. 1). The door assembly 200 comprises one or more door panels 201 being hingably mounted on the vehicle 100. The first member 301 of the hinge assembly 300 is disposed on an internal surface 106 (shown in Figure 6) of the predefined portion of the vehicle 100. The predefined portion of the vehicle 100 for connecting the first member 301 is one of the at least two B-pillars 104. In this embodiment, there are at least two first members 301 (Figure 5) and at least two second members 302 because there are two separate hinge assemblies for mounting the door panel 201. The predefined portion of the vehicle 100 is one of the at least two B-pillars 104 (shown in Figure 4) of the frame assembly 101 of the vehicle 100 (shown in Figure 1). The one of the at least two B-pillars 104 is configured to be connected to the first member 301. The door panel 201 of the door assembly 200 are being configured to swingably move between a closed and an opened condition to facilitate an entry and an exit of a user of the vehicle 100. A first member 301 (shown in Figure 7) and second member 302 (shown in Figure 7) are plate members which are being configured to enable the adjustment of the door panel 201 in the plurality of directions. In one embodiment, the first member 301 and the second member 302 are formed in a shape of a plate. The first member 301, as a plate member, is provided with at least two planar surfaces. The at least two planar surfaces of the first member 301 include a planar surface-A (not shown) and a planar surface-B, 301b. In an assembled condition, the planar surface-A (not shown) interfaces with the internal surface 106 of one of the at-least two B-pillars 104. The planar surface-B, 301b is disposed opposite to the planar surface-A (not shown). Similarly, the second member 302, as a plate member, is provided with at least two planar surfaces. The at least two planar surfaces of the second member 302 are a planar surface-C (not shown) and a planar surface-D, 302d. In an assembled condition, the planar surface-C (not shown) interfaces with a side of the door panel 201. The side of the door panel 201 faces interior of the vehicle 100 when the door panel 201 is in the closed condition. The planar surface-D, 302d is disposed opposite to the planar surface-C (not shown). The plurality of directions comprises a direction along the lateral axis L-L’ (shown in Figure 4) of the vehicle 100, a direction along the longitudinal axis D-D’ (shown in Figure 4) of the vehicle 100 and a direction perpendicular to the lateral axis L-L’ of the vehicle 100. The first member 301 of the hinge assembly 300 is disposed on the one B-pillar of the at-least two B-pillars 104 which is the predefined portion of the vehicle 100 while the second member 302 is attached on an internal surface 203 of the door panel 201 which makes the hinge assembly 300 being internally mounted which contributes to improved security. The first member 301 of the hinge assembly 300 is disposed on an internal surface 106 of one of the at-least two B-pillars 104 . Similar configuration is achieved on the other B-pillars as well on the other side of the vehicle 100. By concealing the hinge assembly 300 within the internal surface 203 of the door panels 201, the risk of tampering or forced entry is reduced as it becomes more challenging for potential thieves to access the vehicle 100 due to enhanced passenger safety and vehicle security. This internally mounted hinge assembly 300 facilitates better gap and flush between the door assembly 200 and the surrounding body panels during closed condition (shown in Figure 14). This also results in a more polished and harmonious exterior appearance, improving the overall fit and finish of the vehicle 100. Unlike externally mounted hinge assemblies which are visible from the outside and can disrupt the vehicle's 100 design flow. This internally mounted hinge assembly 300 provides a cleaner and more streamlined appearance. Further, the internal mounting of the hinge assembly 300 provides better protection from the environmental elements such as rust, dirt, mud and water and potential damage from accidental impacts. This enhances the overall aesthetics of the vehicle 100, making it more visually appealing to consumers as the door panels 201 flush completely with the vehicle’s 100 front portion 102 (shown in Figure 4).
[00051] The door assembly 200 comprises a striker member 204 which is attached to a predefined portion of the vehicle 100. The striker member 204 is configured to receive at least one predefined portion of the door panel 201 at the closed condition of the door panel 201.The adjustment of the door panel 201 is configured to achieve an appropriate alignment of the door panel 201 with the striker member 204. A plurality of fasteners 305-1 are configured to mount the first member 301 to the internal surface 106 of one of the at least two B-pillars 104 of the vehicle 100. The plurality of fasteners 305-2 are being configured to attach the second member 302 on the door panel 201 of the vehicle100. The plurality of fasteners 305-1, 305-2 are configured to be received in the plurality of holes 304 of the first member 301 and the second member 302 respectively, such that the door panel 201 is configured to be adjusted in the plurality of directions while the plurality of fasteners 305-1,305-2 are partially fastened into the plurality of holes 304.
[00052] Further, in one aspect of the invention, the door assembly 200 comprises a niche 205. The niche 205 is provided on the internal surface 203 of the door panel 201. The niche 205 receives and stores a plurality of articles like water bottle, newspaper and magazine etc. Further, door assembly 200 is provided with a lock 206. The lock 206 secures the door assembly 200 in the closed condition.
[00053] Figure 6 illustrates a perspective view of the hinge assembly 300 in one embodiment of the invention. Figure 7 illustrates a perspective view of the hinge assembly 300 showing an axis P-P’ in one embodiment of the invention. Figure 8 illustrates an exploded view of the hinge assembly 300 in one embodiment of the invention. Figure 9 illustrates another exploded view of the hinge assembly 300 in one embodiment of the invention. Figure 6, Figure 7, Figure 8 and Figure 9 have been taken together for discussion. The hinge assembly 300 comprises the first member 301 being attached to a predefined portion of the frame assembly 101 of the vehicle 100 and the second member 302 being attached to the door panel 201. The hinge assembly 300 also comprises a pivot member 303 being configured to pivotably connect the first member 301 and the second member 302The plurality of holes 304 is provided on the first member 301 and the second member 302. The plurality of holes 304 have an oblongated profile to enable an adjustment of the door panel 201 in a plurality of directions. The plurality of holes 304 provide vertical as well as horizontal adjustment capability thereby allowing the door assembly 200 to be adjusted for proper alignment with the striker member 204 that secures the door assembly 200 in closed condition. By adjusting the vertical as well as horizontal position of the first member 301 and the second member 302 through the plurality of holes 304, the alignment of the door panel 201 can be fine-tuned to ensure a proper fit and smooth operation. This feature is especially important for achieving uniform gaps and flushness between the door assembly 200 and the surrounding body components of the vehicle 100. This feature also ensures that the door panels 201 are locked securely without the need for reworking during the assembly line process after manufacturing the product. Since, proper locking is essential for passenger safety and overall vehicle security, said features implement the hinge assembly 300 with reliable design where the risk of door assembly 200 misalignment or malfunction is minimized thereby reducing the need for additional adjustments leading to increased assembly line efficiency and cost savings.
[00054] Further, the rear portion 103 of the vehicle 100 is configured to have a recess. The recess is configured to accommodate a peripheral portion of the door panel 201 in order to enable a flush closing of the door panel 201 with a body of vehicle 100. The predefined portion of the vehicle 100 for connecting the first member 301 is one of the at least two B-pillars 104. In one of the embodiments of the present invention, the door panel 201 is a half door panel. The half door panel shuts a bottom half of a doorway while upper half of the doorway remains open. The half door panel offers a protection from the rain, mud, muck and other elements, without obstructing the natural ventilation and without compromising with the safety of the user of the vehicle 100. Further, the half door panel does not cause substantial increase in weight of the vehicle 100 which can affect mileage, fuel efficiency and costing of the vehicle.
[00055] The first member 301 of the hinge assembly 300 is disposed on an internal surface 106 of the predefined portion of the vehicle 100. The predefined portion of the vehicle 100 for connecting the first member 301 is one of the at least two B-pillars 104. The pivot member 303 is a shaft which is being made up of a material having a low friction on a peripheral surface of the shaft. The material having a low friction are the materials with low coefficient of friction like polyimide, PEEK (Polyether ether ketone), PPS (Polyphenylene sulphide), Nylon, Acetal and Polyester. The shaft belongs to a group comprising pins, rivets and bolts. The first member 301 and the second member 302 comprise a plurality of pivot openings 306. The plurality of pivot openings 306 are configured to receive the pivot member 303 in a hollow cavity which is formed upon an alignment of the plurality of pivot openings 306 along a pivot axis P-P’ to enable a pivotable connection between the first member 301 and the second member 302. A plurality of spacer members 307, 308, 309, 310 are configured to affix the pivot member 303 into the hollow cavity upon the alignment of the first member 301 and the second member 302 along the pivot axis P-P. The plurality of spacer members 307, 308, 309, 310 are made up of the material having low-friction. The material having a low friction are the materials with low coefficient of friction like polyimide, PEEK (Polyether ether ketone), PPS (Polyphenylene sulphide) , Nylon, Acetal and Polyester. The plurality of spacer members 307, 308, 309, 310 comprises a top bush 307, a bottom bush 308 and a pair of middle bushes 309, 310. To ensure smooth and friction-free rotation of the hinge assembly 300, a lubricating material such as nylon can be used. The lubricating material being that of a low-friction allows the hinge assembly 300 to operate freely without the need for additional lubrication. Further, the combination of the top bush 307, the bottom bush 308 and the pair of middle bushes 309, 310 along with the lubricating properties ensures that the hinge operates smoothly and efficiently during the opening and closing of the door panels 201.
[00056] Figure 10 illustrates a side view of the vehicle 100 having the door assembly in closed condition in one embodiment of the invention. Figure 11 illustrates the top view of the vehicle 100 having the door assembly in closed condition (detail B) and opened condition (detail A) in one embodiment of the invention. Figure 12 illustrates an expanded view of the door assembly in opened condition (detail A) in one embodiment of the invention. Figure 13 illustrates an expanded view of the door assembly in closed condition (detail B) one embodiment of the invention. Figure 10, Figure 11, Figure 12 and Figure 13 have been taken together for discussion. The vehicle 100 comprises a front portion 102, a rear portion 103, and a frame assembly 101. The frame assembly 101 comprises at least two B-pillars 104 and at least two C-pillars 105. The at least two B-pillars 104 are disposed between the front portion 102 and the rear portion 103. One of the at least two B-pillars 104 and one of the at least two C-pillars 105 are provided on each of a right side of the vehicle 100. One of the at least two B-pillars 104 and one of the at least two C-pillars 105 are provided on each of a left side of the vehicle 100. The at least two C-pillars 105 are disposed in the rear portion 103 of the vehicle 100. The vehicle 100 comprises a door assembly 200, being hingably attached to the vehicle 100. The door panel 201 of the door assembly 200 swingably moves between a closed and an opened condition to facilitate an entry and an exit of a user of the vehicle 100. In the vehicle 100, a cushioning is present on a surface of the peripheral portion of the door panel 201 in contact with the recess. The cushioning dampens any shock impulse caused by a movement of the door panel 201 between a closed and an opened condition. The door panel 201 is provided with the thickness which is relatively less than the thickness of door panels in the existing art. Reduction in the thickness of the door panel 201 not only helps in achieving space optimization but also makes the ingress and egress convenient. The door panel 201 does not cause any obstruction during the ingress and the egress due to reduced thickness. Reduction in the thickness of the door panel 201 also reduces the weight of the door panel 201 thereby moving of the door panel 201 during opening and closing becomes easy. Reduced weight of the door panel 201 does not cause the addition of unnecessary weight to the vehicle.
[00057] The disclosed invention also relates to a method 400 for an adjustment of a door panel 201 of a door assembly 200 in a plurality of directions during assembly of a vehicle 100. The method 400 is illustrated in Figure 14, the method 400 comprises a first step S1, a second step S2, a third step S3, and a fourth step S4. The first step S1 includes loosening of a plurality of fasteners 305-1, 305-2. The plurality of fasteners 305-1, 305-2 are fastened through a plurality of holes 304. The plurality of holes 304 has an oblongated profile. The plurality of holes 304 is provided on a first member 301 and a second member 302 of a hinge assembly 300 of the door assembly 200. This leads to loosening of an attachment of the door panel 201 from the first member 301 of the hinge assembly 300. The second member 302 being connected to a frame assembly 101 of the vehicle 100. The second step S2 includes selection of one direction from a plurality of directions. The plurality of directions comprises a direction along a longitudinal axis D-D’ of the vehicle 100, a direction along a lateral axis L-L’ of the vehicle 100, and a direction perpendicular to the lateral axis L-L’ of the vehicle 100. In the third step S3 the door panel 201 is moved along one or more of the plurality of directions along with the plurality of fasteners 305-1, 305-2 within the oblongated profile of the plurality of openings 304. Thus, enabling an alignment of the door panel 201 with a striker member 204 of the door assembly 200. The striker member 204 receives at least one predefined portion of the door panel 201 at a closed condition of the door panel 201. In the fourth step S4, the plurality of fasteners 305-1 on the first member 301 are tightened. The plurality of fasteners 305-2 on the second member 302 is also tightened in order to fix a position of the door panel 201 on the vehicle 100.
[00058] This simplicity makes the manufacturing process more cost-effective compared to complex casting methods involved in hinge casting. The use of metal along with the lubricating material provides smooth rotation of the door panel 201, enhances the overall durability and longevity of the hinge assembly 300. This can lead to reduced maintenance and replacement costs over the vehicle's 100 lifetime. The said combination also eliminates need for separate bushing components thereby simplifying the design and assembly of the hinge assembly 300. This further aids in weight and width reduction of the vehicle 100.
[00059] It is to be noted that the second member 302 of the hinge assembly 300 can be strategically disposed on the door assembly 200 while considering the specific requirements of the vehicle's design and functionality. This placement of the second member 302 ensures that the door panel 201 operate smoothly during opening and closing while maintaining proper alignment. The plurality of fasteners 305-1, 305-2 secure the first member 301 and the second member 302 of the hinge assembly 300 in place, ensuring they remain firmly fixed to the door assembly 200 during operation.
[00060] The embodiments of this invention are not limited to door assembly of the vehicle and can also cover other areas of application where the hinge assembly is required to connect two or more components including doors in non-vehicular applications. As used in this specification and the appended claims, the singular forms “a,” “an” and “the” can include plural referents unless the content clearly indicates otherwise. Further, when introducing elements/components/etc. of the assembly/system described and/or illustrated herein, the articles “a”, “an”, “the”, and “said” are intended to mean that there is one or more of the element(s)/component(s)/etc. The terms “comprising”, “including”, and “having” are intended to be inclusive and mean that there may be additional element(s)/component(s)/etc. other than the listed element(s)/component(s)/etc.
[00061] This written description uses examples to provide details on the disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any apparatuses, assemblies, devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
[00062] It is to be understood that the aspects of the embodiments are not necessarily limited to the features described herein. Many modifications and variations of the present subject matter are possible in the light of above disclosure.

List of Reference numerals:

100 Vehicle
101 Frame assembly
102 Front portion
103 Rear portion
104 At least two B-pillars
105 At least two C-pillars
106 Internal surface of the predefined portion
200 Door assembly
201 Door panel
203 Internal surface of the door panel
204
205
206 Striker member
Niche
Lock
300 Hinge assembly
301
301b First member
Planar surface-B
302
302d Second member
Planar surface-D
303 Pivot member
304 Plurality of holes
305-1,305-2
306 Plurality of fasteners
Plurality of pivot openings
307, 308, 309, 310 Plurality of spacer members
307 Top bush
308 Bottom bush
309, 310
L-L
D-D
P-P’
400
S1
S2
S3
S4 Pair of middle bushes
Lateral axis of the vehicle
Longitudinal axis of the vehicle
Pivot axis of the hinge assembly
Method
First step
Second step
Third step
Fourth step
, Claims:We Claim:
1. A door assembly (200) for a vehicle (100) having a frame assembly (101), the door assembly (200) comprising:
a door panel (201), the door panel (201) being hingably mounted on the vehicle (100);
a hinge assembly (300), the hinge assembly (300) being configured to hingably mount the door panel (201) on the vehicle (100), the hinge assembly (300) comprising:
a first member (301), the first member (301) being attached to a predefined portion of the vehicle (100);
a second member (302), the second member (302) being attached to the door panel (201);
a pivot member (303), the pivot member (303) being configured to pivotably connect the first member (301) and the second member (302); and
a plurality of holes (304), the plurality of holes (304) being provided on the first member (301) and the second member (302), the plurality of holes (304) having an oblongated profile to enable an adjustment of the door panel (201) in a plurality of directions.
2. The door assembly (200) as claimed in claim 1, wherein the first member (301) and the second member (302) being plate members, the plate members being configured to enable the adjustment of the door panel (201) in the plurality of directions and the plurality of directions comprising:
a direction along a lateral axis L-L’ of the vehicle (100), a direction along a longitudinal axis D-D’ of the vehicle (100) and a direction perpendicular to the lateral axis L-L’ of the vehicle (100).
3. The door assembly (200) as claimed in claim 1, wherein the first member (301) of the hinge assembly (300) being disposed on an internal surface (106) of the predefined portion of the vehicle (100), and the second member (302) being attached on an internal surface (203) of the door panel (201), the door panel (201) being configured to swingably move between a closed and an opened condition to facilitate an entry and an exit of a user of the vehicle (100).
4. The door assembly (200) as claimed in claim 3, wherein the door assembly (200) comprises a striker member (204), the striker member (204) being attached to a predefined portion of the vehicle (100) and the striker member (204) being configured to receive at least one predefined portion of the door panel (201) at the closed condition of the door panel (201), and the adjustment of the door panel (201) being configured to achieve an appropriate alignment of the door panel (201) with the striker member (204).
5. The door assembly (200) as claimed in claim 1, wherein a plurality of fasteners (305-1) being configured to mount the first member (301) to the predefined portion of the vehicle (100), and the plurality of fasteners (305-2) being configured to attach the second member (302) on the door panel (201) of the vehicle (100), the plurality of fasteners (305-1, 305-2) being configured to be received in the plurality of holes (304) such that the door panel (201) being configured to be adjusted in the plurality of directions while the plurality of fasteners (305-1, 305-2) being partially fastened into the plurality of holes (304).
6. The door assembly (200) as claimed in claim 1, wherein the hinge assembly (300) comprises at least two first members (301) and at least two second members (302) and the predefined portion of the vehicle (100) being a B-pillar (104) of the frame assembly (101) of the vehicle (100).
7. The door assembly (200) as claimed in claim 3, wherein the internal surface (203) of the door panel (201) being provided with a niche (205), the niche (205) being configured to receive and store a plurality of articles.
8. A hinge assembly (300), the hinge assembly (300) being configured to hingably mount a door panel (201) on a vehicle (100), the hinge assembly (300) comprising:
a first member (301), the first member (301) being attached to a predefined portion of a frame assembly (101) of the vehicle (100);
a second member (302), the second member (302) being attached to the door panel (201);
a pivot member (303), the pivot member (303) being configured to pivotably connect the first member (301) and the second member (302); and
a plurality of holes (304), the plurality of holes (304) being provided on the first member (301) and the second member (302), the plurality of holes (304) having an oblongated profile to enable an adjustment of the door panel (201) in a plurality of directions.
9. The hinge assembly (300) as claimed in claim 8, wherein the pivot member (303) being a shaft.
10. The hinge assembly (300) as claimed in claim 9 wherein the first member (301) and the second member (302) comprise a plurality of pivot openings (306) the plurality of pivot openings (306) being configured to receive the pivot member (303) in a hollow cavity, the hollow cavity being formed upon an alignment of the plurality of pivot openings (306) along a pivot axis P-P’ to enable a pivotable connection between the first member (301) and the second member (302).
11. The hinge assembly (300) as claimed in claim 10, wherein a plurality of spacer members (307, 308, 309, 310) being configured to affix the pivot member (303) into the hollow cavity upon the alignment of the first member (301) and the second member (302) along the pivot axis P-P, and the plurality of spacer members (307, 308, 309, 310) comprising a top bush (307), a bottom bush (308) and a pair of middle bushes (309, 310).
12. A vehicle (100) comprising:
a front portion (102), the front portion (102) being configured to accommodate a driver seat;
a rear portion (103), the rear portion (103) being configured to accommodate a passenger seat;
a frame assembly (101), the frame assembly (101) being configured to provide a skeletal support to the vehicle (100), the frame assembly (101) comprising:
at least two B-pillars (104), the at least two B-pillars (104) being disposed between the front portion (102) and the rear portion (103); and
at least two C-pillars (105), the at least two C-pillars (105) being disposed in the rear portion (103) of the vehicle (100);
a door assembly (200), the door assembly (200) being hingably attached to the vehicle (100), the door assembly (200) comprising:
a door panel (201), the door panel (201) being hingably mounted on the vehicle (100); and
a hinge assembly (300), the hinge assembly (300) being configured to hingably mount the door panel (201) on the vehicle (100), the hinge assembly (300) comprising:
a first member (301), the first member (301) being attached to a predefined portion of the frame assembly (101) of the vehicle (100);
a second member (302), the second member (302) being attached to the door panel (201);
a pivot member (303), the pivot member (303) being configured to pivotably connect the first member (301) and the second member (302); and
a plurality of holes (304), the plurality of holes (304) being provided on the first member (301) and the second member (302), the plurality of holes (304) having an oblongated profile to enable an adjustment of the door panel (201) in a plurality of directions.
13. The vehicle (100) as claimed in claim 12, wherein the rear portion (103) being configured to have a recess, the recess being configured to accommodate a peripheral portion of the door panel (201) in order to enable a flush closing of the door panel (201) with a body of vehicle (100).
14. The vehicle (100) as claimed in claim 12, wherein the predefined portion of the vehicle (100) for connecting the first member (301) being an internal surface (106) of one of the at least two B-pillars (104).
15. The vehicle (100) as claimed in claim 13, wherein a cushioning being provided on a surface of the peripheral portion of the door panel (201) in contact with the recess in order to dampen a shock impulse, the shock impulse being caused by a movement of the door panel (201) between a closed condition and an opened condition.
16. A method (400) for an adjustment of a door panel (201) of a door assembly (200) in a plurality of directions during assembly of a vehicle (100), the method (400) comprising the steps of:
a first step (S1), the first step (S1) including loosening a plurality of fasteners (305-1, 305-2), the plurality of fasteners (305-1, 305-2) being fastened through a plurality of holes (304), the plurality of holes (304) having an oblongated profile and the plurality of holes (304) being provided on a first member (301) and a second member (302) of a hinge assembly (300) of the door assembly (200), thereby loosening an attachment of the door panel (201) from the first member (301) of the hinge assembly (300), wherein the second member (302) being connected to a frame assembly (101) of the vehicle (100);
a second step (S2), the second step (S2) including selecting one direction from a plurality of directions, the plurality of directions comprising a direction along a longitudinal axis D-D’ of the vehicle (100), a direction along a lateral axis L-L’ of the vehicle (100), and a direction perpendicular to the lateral axis L-L’ of the vehicle (100);
a third step (S3), the third step (S3) including moving the door panel (201) along one or more of the plurality of directions along with the plurality of fasteners (305-1, 305-2) within the oblongated profile of the plurality of openings (304) to enable an alignment of the door panel (201) with a striker member (204) of the door assembly (200), the striker member (204) being configured to receive at least one predefined portion of the door panel (201) at a closed condition of the door panel (201); and
a fourth step (S4), the fourth step (S4) including tightening the plurality of fasteners (305-1) on the first member (301) and the plurality of fasteners (305-2) on the second member (302) thereby fixing a position of the door panel (201) on the vehicle (100).

Dated this the 27th day of September 2023
(Digitally Signed)
Sudarshan Singh Shekhawat
IN/PA-1611
Agent for the Applicant